“Click”, “Pop” or “Creek” Sound from Left or Right Outer Cowl Corner / Base of “A” Pillar Area

INTRODUCTION

This bulletin provides a repair procedure to address customer concerns of a “Click”, “Pop” or “Creek” sound heard coming from either the left or right side around the rear corners of the cowl / engine compartment / base of “A” pillar area.

PUNCH TESTER TOOL INFORMATION

The punch tester was originally provided to retailers located in salt-belt states to perform Product Campaign WVX-34. The following information is for retailers which do not already have (or may have misplaced) their punch tester. Currently, we have a very limited number of punch testers available. A punch tester will be supplied upon request strictly as a “loaner”. The Punch Tester Request Form must be filled out and faxed to the Parts Collection Center. Upon receipt of the request form, the punch tester will be shipped via UPS Ground or Second Day Air depending upon the “Need by Date” requested. The tool will be shipped in a UPS Express “Large Box” measuring 18x13x3. A pre-printed UPS label will also be provided for the return shipping. Therefore, the same size and style box needs to be used for the return shipping. These boxes may be requested directly from UPS if you do not have them. Using a box other than the size listed can create a delay in return shipping and possibly result in charges to the retailer. The punch tester must be returned immediately upon repair completion. Failure to return the punch tester within two weeks of the request submission or the return of a damaged tool will result in a charge of $500.00 being added to the requesting retailer’s monthly statement.

NOTE: Refer to the last page of this bulletin for the Punch Tester Request Form.

SERVICE PROCEDURE / INFORMATION

Once the sound has been confirmed and isolated to the area described in the introduction of this bulletin, the fender for the side of the vehicle in question will need to be removed following the procedure outlined in the applicable Service Manual. It may be necessary to use Chassis Ears to determine the precise source of the sound. The left fender is removed in the photo below.

To avoid unnecessary distortion of the affected panels, always use a block of wood (or equivalent) along with a helper to firmly support the panel from behind when making the punches with the punch tool.

Another area which may be the source of these sounds is shown in the photos below. Although the right fender is removed in the photo, the structures are symmetrical side to side. Separate the layers of sheet metal using a flat-blade screwdriver but use caution not to tear or separate any spot welds.

IMPORTANT REMINDERS:

When these procedures are complete, always touch up, seam seal or undercoat any exposed bare metal areas to prevent rust from developing.

Adding additional welds to the body structure is NOT PERMITTED as doing so may have an effect on the crash-worthiness of the vehicle.

WARRANTY / CLAIM INFORMATION

For vehicles within the Basic New Car Limited Warranty period, this repair may be claimed using the following information:

LABOR DESCRIPTION

LABOR
OPERATION #

FAIL
CODE

LABOR
TIME

RIGHT FRONT COWL REPAIR FOR POP/ CREEK SOUND

A905-001

OBM-25

1.2

LEFT FRONT COWL REPAIR FOR POP/ CREEK SOUND

A905-002

1.2

BOTH FRONT COWLS REPAIRED FOR POP/

CREEK SOUND

A905-004

1.8

NOTE: Up to $3.00 can be claimed in Sublet to cover the cost of touch-up materials as needed.